Method for manufacturing an LED chip package structure

ABSTRACT

An LED chip package structure with thick guiding pin includes a plurality of conductive pins separated from each other, an insulative casing, a plurality of LED chips, and a packaging colloid. The insulative casing covers a bottom side of each conductive pin to form an injection concave groove for exposing a top surface of each conductive pin. Two lateral sides of each conductive pin are extended outward from the insulative casing. The LED chips are arranged in the injection concave groove, and each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins. In addition, the packaging colloid is filled into the injection concave groove for covering the LED chips.

RELATED APPLICATIONS

This application is a Divisional patent application of application Ser. No. 11/861,757, filed on 26 Sep. 2007 now U.S. Pat. No. 7,671,374. The entire disclosure of the prior application, Ser. No. 11/861,757, from which an oath or declaration is supplied, is considered a part of the disclosure of the accompanying Divisional application and is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an LED chip package structure and a method for manufacturing the same, and particularly relates to an LED chip package structure with a plurality of thick guiding pins and a method for manufacturing the same.

2. Description of the Related Art

FIG. 1 shows a cross-sectional, schematic view of a vertical LED chip package structure of the prior art. The vertical LED chip package structure includes an insulative substrate 1 a, a lead frame 2 a, an LED chip 3 a, and a fluorescent colloid 4 a.

The lead frame 2 a has two conductive pins 20 a, 21 a respectively extended along two opposite lateral sides and bent twice, so that the bottom faces of the two conductive pins 20 a, 21 a are electrically connected with a PCB 5 a. In addition, the conductive pin 20 a has a positive electrode area 200 a, and the conductive pin 21 a has a negative electrode area 210 a.

Moreover, the LED chip 3 a has a positive electrode side 300 a and a negative electrode side 310 a. The LED chip 3 a is disposed on the conductive pin 20 a directly, so that the positive electrode side 300 a of the LED chip 3 a is electrically connected with the positive electrode area 200 a of the conductive pin 20 a directly. The negative electrode side 310 a of the LED chip 3 a is electrically connected with the negative electrode area 210 a of the conductive pin 21 a via a leading wire 6 a.

The fluorescent colloid 4 a is covered on the LED chip 3 a for protecting the LED chip 3 a. Therefore, the vertical LED chip package structure should project light upwardly (such as the arrows in FIG. 1).

However, the vertical LED chip package structure of the prior art has some defects, as follows:

1. If the conductive pins (20 a, 21 a) want to electrically connect with the PCB 5 a, the conductive pins (20 a, 21 a) need to be bent twice. Therefore, the complexity of the manufacturing process should be increased.

2. The thickness of the conductive pins (20 a, 21 a) is very thin, so that the heat-dissipating area of the conductive pins (20 a, 21 a) is very small. Therefore, the heat-dissipating capability cannot be promoted.

3. The thickness of the conductive pins (20 a, 21 a) is very thin, so that the supply of power source cannot be increased. Therefore, the LED chip cannot generate high light-emitting efficiency.

SUMMARY OF THE INVENTION

One particular aspect of the present invention is to provide an LED chip package structure with a plurality of thick guiding pins and a method for manufacturing the same. The present invention has some advantages, as follows:

1. The conductive pins can be electrically connected with the PCB without bending the conductive pins. Therefore, the manufacturing process of the present invention is simplification.

2. The thickness of the conductive pins is thick, so that the heat-dissipating area of the conductive pins is increased. Therefore, the heat-dissipating capability can be promoted in the present invention.

3. The thickness of the conductive pins is thick, so that the supply of power source can be increased. Therefore, the LED chip can generate high light-emitting efficiency.

In order to achieve the above-mentioned aspects, the present invention provides a method for manufacturing an LED chip package structure with a plurality of thick guiding pins, comprising: providing a metal substrate that has a plurality of conductive pins extended and suspended outward, wherein each conductive pin has a concave groove formed on a bottom surface thereof; covering a bottom side of each conductive pin with an insulative casing to form an injection concave groove for exposing a top side of each conductive pin; arranging a plurality of LED chips in the injection concave groove, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins; filling a package colloid into the injection concave groove for covering the LED chips; and cutting the conductive pins to form the LED chip package structure with the thick guiding pins.

In order to achieve the above-mentioned aspects, the present invention provides a method for manufacturing an LED chip package structure with a plurality of thick guiding pins, comprising: providing a metal substrate that has a plurality of conductive pins extended outward to fix two lateral sides of each conductive pin, wherein each conductive pin has a concave groove formed on a bottom surface thereof; covering a bottom side of each conductive pin with an insulative casing to form an injection concave groove for exposing a top side of each conductive pin; arranging a plurality of LED chips in the injection concave groove, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins; filling a package colloid into the injection concave groove for covering the LED chips; and cutting the conductive pins to form the LED chip package structure with the thick guiding pins.

In order to achieve the above-mentioned aspects, the present invention provides a method for manufacturing an LED chip package structure with a plurality of thick guiding pins, comprising: providing a metal substrate that has a plurality of conductive pins extended and suspended outward, and a plurality of strengthening ribs joint between each two conductive pins, wherein each conductive pin has a concave groove formed on a bottom surface thereof; covering a bottom side of each conductive pin with an insulative casing to form an injection concave groove for exposing a top side of each conductive pin; arranging a plurality of LED chips in the injection concave groove, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins; filling a package colloid into the injection concave groove for covering the LED chips; and cutting the conductive pins to form the LED chip package structure with the thick guiding pins.

In order to achieve the above-mentioned aspects, the present invention provides an LED chip package structure with a plurality of thick guiding pins, comprising: a plurality of conductive pins, an insulative casing, a plurality of LED chips, and a packaging colloid. The conductive pins are separated from each other. The insulative casing covers a bottom side of each conductive pin to form an injection concave groove for exposing a top surface of each conductive pin. The LED chips are arranged in the injection concave groove, and each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins. The packaging colloid is filled into the injection concave groove for covering the LED chips.

It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed. Other advantages and features of the invention will be apparent from the following description, drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The various objects and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawings, in which:

FIG. 1 is a cross-sectional, schematic view of a vertical LED chip package structure of the prior art;

FIG. 2 is a flowchart of a method for manufacturing an LED chip package structure with a plurality of thick guiding pins according to the first embodiment of the present invention;

FIG. 3 is a perspective, schematic view of a metal substrate according to the first embodiment of the present invention;

FIG. 4 is a top, schematic view of a metal substrate according to the first embodiment of the present invention;

FIG. 5 is a cross-sectional view along line 5-5 of a metal substrate shown in FIG. 2;

FIG. 6 is a perspective, schematic view of a metal substrate being covered with an insulative casing according to the first embodiment of the present invention;

FIG. 7 is a perspective, schematic view of a plurality of LED chips respectively and electrically connected with a plurality of conductive pins according to the first embodiment of the present invention;

FIG. 8 is a lateral, schematic view of a first arrangement of a plurality of LED chips according to the present invention;

FIG. 9 is a perspective, schematic view of a package colloid filled into an injection concave groove according to the first embodiment of the present invention;

FIG. 10 is one perspective, schematic view of one part of each conductive pin being cut according to the first embodiment of the present invention;

FIG. 11 is another perspective, schematic view of one part of each conductive pin being cut according to the first embodiment of the present invention;

FIG. 12 is a lateral, schematic view of a second arrangement of a plurality of LED chips according to the present invention;

FIG. 13 is a lateral, schematic view of a third arrangement of a plurality of LED chips according to the present invention;

FIG. 14 is a lateral, schematic view of a fourth arrangement of a plurality of LED chips according to the present invention;

FIG. 15 is a flowchart of a method for manufacturing an LED chip package structure with a plurality of thick guiding pins according to the second embodiment of the present invention;

FIG. 16 is a perspective, schematic view of a metal substrate being covered with an insulative casing according to the second embodiment of the present invention;

FIG. 17 is a flowchart of a method for manufacturing an LED chip package structure with a plurality of thick guiding pins according to the third embodiment of the present invention;

FIG. 18 is a perspective, schematic view of a metal substrate being covered with an insulative casing according to the third embodiment of the present invention;

FIG. 19 is a perspective, schematic view of a metal substrate being covered with a plurality of insulative casings according to the first embodiment of the present invention;

FIG. 20 is a perspective, schematic view of a metal substrate being covered with a plurality of insulative casings according to the second embodiment of the present invention; and

FIG. 21 is a perspective, schematic view of a metal substrate being covered with a plurality of insulative casings according to the third embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 2 to 5, the first embodiment of the present invention provides a method for manufacturing an LED chip package structure with a plurality of thick guiding pins.

The method comprises: firstly, referring to FIG. 3, providing a metal substrate 1 that has a plurality of conductive pins 11 extended and suspended outward, and each conductive pin 11 having a concave groove 111 formed on a bottom surface thereof (S100). The conductive pins 11 are separated from each other. Each concave groove 111 can be a half etching concave groove. The metal substrate 1 and the conductive pins 11 are formed via an etching method, a punching method, or any forming method. The metal substrate 1 has an electroplated protection layer 110 formed on a surface thereof. It means that each conductive pin 11 has an electroplated protection layer 110 formed on a surface thereof. In addition, each conductive pin 11 has a thickness between 0.4 mm and 3 mm. Of course, the thickness of each conductive pin 11 should be more than 0.4 mm according to user's requirement.

Referring to FIG. 6, after the step of S100, the method further comprises: covering a bottom side of each conductive pin 11 with an insulative casing 2 to form an injection concave groove 20 for exposing a top side of each conductive pin 11 (S102). The insulative casing 2 is filled into a plurality of non-conductive areas 21 between each two conductive pins 11. In the step of S102, the bottom sides of the conductive pins 11 are covered with the insulative casing 2 via an injection molding method or any forming method.

Referring to FIGS. 7 and 8, after the step of S102, the method further comprises: arranging a plurality of LED chips 3 in the injection concave groove 20, and each LED chip 3 having a positive electrode side 30 and a negative electrode side 31 respectively and electrically connected with different conductive pins 11 (S104).

In other words, the positive electrode side 30 and the negative electrode side 31 of each LED chip 3 are respectively and selectively arranged on a lower surface and an upper surface of each LED chip 3. Each LED chip 3 is arranged on a corresponding positive electrode portion 1100. Therefore, the positive electrode side 1100 of each LED chip 3 is directly and electrically connected with the corresponding positive electrode portion 1100, and the negative electrode side 31 of each LED chip 3 is electrically connected with a corresponding negative electrode portion 1101 via a leading wire 4.

Referring to FIG. 9, after the step of S104, the method further comprises: filling a package colloid 5 into the injection concave groove 20 for covering the LED chips 3 (S106). The package colloid 5 can be made of an epoxy material or a silicone material.

Referring to FIGS. 10 and 11, after the step of S106, the method further comprises: cutting the conductive pins 11 to form the LED chip package structure with the thick guiding pins (S108). Therefore, two lateral sides of each conductive pin 11 are appeared from two lateral sides of the insulative casing 2 for soldering process.

Referring to FIG. 12, the positive electrode side 30 and the negative electrode side 31 of each LED chip 3 are respectively and sequentially arranged on a lower surface and an upper surface of each LED chip 3. Each LED chip 3 is arranged on a corresponding positive electrode portion 1100′. Therefore, the positive electrode side 1100′ of each LED chip 3 is directly and electrically connected with the corresponding positive electrode portion 1100′, and the negative electrode side 31 of each LED chip 3 is electrically connected with a corresponding negative electrode portion 1101′ via a leading wire 4.

Referring to FIG. 13, the insulative casing 2 further comprises a plurality of non-conductive areas 21′ between each two conductive pins 11. Moreover, a positive electrode side 30′ and a negative electrode side 31′ of each LED chip 3′ are arranged on an upper surface of each LED chip 3′. Each LED chip 3′ is separately arranged on each non-conductive area 21′. Therefore, the positive electrode side 30′ and the negative electrode side 31′ of each LED chip 3′ are respectively and electrically connected with the adjacent positive and negative electrode portions 1100′, 1101′ via two leading wires 4′ by a wire-bounding method.

Referring to FIG. 14, a positive electrode side 30″ and a negative electrode side 31″ of each LED chip 3″ are arranged on a lower surface of each LED chip 3″. Each LED chip 3″ crosses through a corresponding non-conductive area 21″. Therefore, the positive electrode side 30″ and the negative electrode side 31″ of each LED chip 3″ are respectively and electrically connected with the adjacent positive and negative electrode portions 1100″, 1101″ via a plurality of solder balls 4″ by a flip-chip method.

Referring to FIGS. 15 and 16, the second embodiment of the present invention provides a method for manufacturing an LED chip package structure with a plurality of thick guiding pins. The method comprises: firstly, referring to FIG. 16, providing a metal substrate 1′ that has a plurality of conductive pins 11′ extended outward to fix two lateral sides of each conductive pin 11′, and each conductive pin 11′ having a concave groove 111′ formed on a bottom surface thereof (S200). Each concave groove 111′ can be a half etching concave groove. After the step of S200, the method further comprises: covering a bottom side of each conductive pin 11′ with an insulative casing 2′ to form an injection concave groove 20′ for exposing a top side of each conductive pin 11′ (S202). The insulative casing 2′ is filled into a plurality of non-conductive areas 21′ between each two conductive pins 11′.

Furthermore, the next steps of the second embodiment are same as the steps of S104 to S108 in the first embodiment. Therefore, the method further comprises: arranging a plurality of LED chips (not shown) in the injection concave groove 20′, and each LED chip having a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins 11′ (S204); filling a package colloid (not shown) into the injection concave groove 20′ for covering the LED chips (S206); and then cutting the conductive pins 11′ to form the LED chip package structure with the thick guiding pins (S208).

Referring to FIGS. 17 and 18, the third embodiment of the present invention provides a method for manufacturing an LED chip package structure with a plurality of thick guiding pins. The method comprises: firstly, referring to FIG. 18, providing a metal substrate 1″ that has a plurality of conductive pins 11″ extended and suspended outward and a plurality of strengthening ribs 12″ joint between each two conductive pins 11″, and each conductive pin 11″ has a concave groove 111″ formed on a bottom surface thereof (S300). Each concave groove 111″ can be a half etching concave groove. After the step of S300, the method further comprises: covering a bottom side of each conductive pin 11″ with an insulative casing 2″ to form an injection concave groove 20″ for exposing a top side of each conductive pin 11″ (S302). The insulative casing 2″ is filled into a plurality of non-conductive areas 21″ between each two conductive pins 11″.

Furthermore, the next steps of the second embodiment are same as the steps of S204 to S208 in the first embodiment. Therefore, the method further comprises: arranging a plurality of LED chips (not shown) in the injection concave groove 20″, and each LED chip having a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins 11″ (S304); filling a package colloid (not shown) into the injection concave groove 20″ for covering the LED chips (S306); and then cutting the conductive pins 11″ to form the LED chip package structure with the thick guiding pins (S308).

FIGS. 19 to 21 show three perspective, schematic views of a metal substrate being covered with a plurality of insulative casings according to the first, the second and the third embodiment of the present invention, respectively. Referring to FIG. 19, a metal substrate 1 with a plurality of conductive pins 11 is covered with a plurality of insulative casings 2 to form three rows of series LED chip package structure. Referring to FIG. 20, a metal substrate 1′ with a plurality of conductive pins 11′ is covered with a plurality of insulative casings 2′ to form three rows of series LED chip package structure. Referring to FIG. 21, a metal substrate 1″ with a plurality of conductive pins 11″ is covered with a plurality of insulative casings 2″ to form three rows of series LED chip package structure. Therefore, the three types of conductive pins (11, 11′, 11″) and insulative casings (2, 2′, 2″) can be integratedly formed in one piece.

In conclusion, the present invention has some advantages, as follows:

1. The conductive pins can be electrically connected with the PCB without bending the conductive pins. Therefore, the manufacturing process of the present invention is simplification.

2. The thickness of the conductive pins is thick, so that the heat-dissipating area of the conductive pins is increased. Therefore, the heat-dissipating capability can be promoted in the present invention.

3. The thickness of the conductive pins is thick, so that the supply of power source can be increased. Therefore, the LED chip can generate high light-emitting efficiency.

Although the present invention has been described with reference to the preferred best molds thereof, it will be understood that the invention is not limited to the details thereof. Various substitutions and modifications have been suggested in the foregoing description, and others will occur to those of ordinary skill in the art. Therefore, all such substitutions and modifications are intended to be embraced within the scope of the invention as defined in the appended claims. 

1. A method for manufacturing an LED chip package structure with a plurality of thick guiding pins, comprising: providing a metal frame having a plurality of conductive pins extended and suspended from an inner surface thereof, wherein each conductive pin has a concave groove formed on a bottom surface thereof; forming an insulative casing, wherein the insulative casing forms an injection concave groove on a top surface of the conductive pin, wherein the injection concave groove exposes a top surface of the conductive pin, wherein a tip and a root of each conductive pin are exposed outside the opposing lateral walls of the insulative casing, and wherein the concave groove of the conductive pin is covered by the insulative casing; arranging a plurality of LED chips in the injection concave groove, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins; filling a package colloid into the injection concave groove; and forming the LED chip package structure by separating a root of each conductive pin from the metal frame.
 2. The method as claimed in claim 1, wherein the metal frame and the conductive pins are formed via an etching method or a punching method.
 3. The method as claimed in claim 1, wherein the metal frame has an electroplated protection layer formed on a surface thereof and each conductive pin has an electroplated protection layer formed on a surface thereof.
 4. The method as claimed in claim 1, wherein each conductive pin has a thickness between 0.4 mm and 3 mm.
 5. The method as claimed in claim 1, wherein the bottom sides of the conductive pins are covered with the insulative casing via an injection molding method.
 6. The method as claimed in claim 1, wherein the insulative casing is filled into a plurality of non-conductive areas between each two conductive pins, and two lateral sides of each conductive pin are appeared from two lateral sides of the insulative casing for soldering process.
 7. The method as claimed in claim 1, wherein the package colloid is made of an epoxy material or a silicone material.
 8. A method for manufacturing an LED chip package structure with a plurality of thick guiding pins, comprising: providing a metal frame having a plurality of conductive pins extended from the inner surface thereof, wherein the conductive pin joins the inner lateral walls of the metal frame, wherein each conductive pin has a concave groove formed on a bottom surface thereof; forming an insulative casing, wherein the insulative casing forms an injection concave groove on a top surface of the conductive pin, wherein the injection concave groove exposes a top surface of the conductive pin, wherein a tip and a root of each conductive pin are exposed outside the opposing lateral walls of the insulative casing, and wherein the concave groove of the conductive pin is covered by the insulative casing; arranging a plurality of LED chips in the injection concave groove, wherein each LED chip has a positive electrode side and a negative electrode side respectively and electrically connected with different conductive pins; filling a package colloid into the injection concave groove for covering the LED chips; and forming the LED chip package structure by separating a root of each conductive pin from the metal frame.
 9. The method as claimed in claim 8, wherein the metal frame and the conductive pins are formed via an etching method or a punching method.
 10. The method as claimed in claim 8, wherein the metal frame has an electroplated protection layer formed on a surface thereof and each conductive pin has an electroplated protection layer formed on a surface thereof.
 11. The method as claimed in claim 8, wherein each conductive pin has a thickness between 0.4 mm and 3 mm.
 12. The method as claimed in claim 8, wherein the bottom sides of the conductive pins are covered with the insulative casing via an injection molding method. 